Cutting Parameter Optimization when Machining Different Materials

Abstract

Flank wear occurring on the cutting edge increases as machining time goes on. This results in an increase in the cutting force and the surface roughness which leads to product quality deterioration. Predictive time models presented for flank wear, cutting force, and surface roughness in terms of machining conditions show that the parameters under investigation are sensitive to time, where the time factor must be considered not only for flank wear, but also for the power consumed and product quality. The finding in this study is that the dependency of cutting force and surface roughness on time is valid and cannot be ignored. It is found that tool flank wear can be expressed as a function of time in a valid model. A tool life model was constructed as a function of the presented independent variables for different workpiece materials. Optimization results were obtained and presented for maximizing tool life, minimizing production cost, or minimizing production time.